Method for forming articles from plastic sheet material

ABSTRACT

A vacuum-forming operation in which a pair of adjacent compartment liners are formed from a single sheet of thermoplastic material. A sheet of thermoplastic material is disposed to extend over the molds, and is heated, causing it to soften while the molds are held in pivoted position in which the confronting surfaces are substantially spaced from one another. Mold assist-plugs and the molds are then moved. relative to one another, to urge the sheet into general close conformity with the molds. While the sheet of material is still soft, the assist-plugs further are caused to engage the mod frame structure, through the intermediacy of the sheet, pivoting the frame structure and causing adjacent wall portions of the molds to move toward one another and assume their closely spaced position. Air entrapped between the heated sheet and the walls of the mold not provided with the auxiliary section is then evacuated through a number of small ports or vents in the walls, thereby forming on of the desired liners, whereupon the auxiliary section of the other mold is projected and air entrapped between the heated sheet and the mold is evacuated, forming the other of the desired liners with an undercut region. The liners are then cooled, the extended auxiliary mold section is retracted from the undercut region, and the liners are stripped as a unit from the undercut region, and the liners are stripped as a unit from the molds.

Dec. 25, 1973 N. F. HOUGHTON 3,731,394

METHOD FOR FORMTNG ARTICLES FRUM PLASTIC SHEET MATERIAL 3 Sheets-Sheet 1 Filed March 20, 1972 v Dec. 25, 1973 F. HOUGHTON METHOD FOR FORMI NG ARTICLES FROM PLASTIC SHEET MATERIAL 3 Sheets-Sheet 2 Filed March 20, 1972 VA Cl/UM Dec. 25, 1973 N. F. HOUGHTON 3,781,394

METHOD FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL 3 Sheets-Sheet 3 Filed March 20, 1972 53 J] 44 J0 5 .78 :1 42 43 4? I I? :-v 33 60 16 I w 1 Z! is 27 J/Al I 17 Patented Dec. 25 1973 METHOD FOR FORMING ARTICLES FROM PLASTIC SHEET MATERIAL Norman F. Houghton, Connersville, Ind., assignor to Philco-Ford Corporation, Philadelphia, Pa. Filed Mar. 20, 1972, Ser. No. 235,968

The portion of the term of the patent subsequent to Jan. 9, 1990, has been disclaimed Int. Cl. B29c 17/04 US. Cl. 264-89 2 Claims ABSTRACT OF THE DISCLOSURE A vacuum-forming operation in which a pair of adjacent compartment liners are formed from a single sheet of thermoplastic material. A sheet of thermoplastic material is disposed to extend over the molds, and is heated, causing it to soften while the molds are held in pivoted position in which the confronting surfaces are substantially spaced from one another. Mold assist-plugs and the molds are then inoved, relative to one another, to urge the sheet into general close conformity with the molds. While the sheet of material is still soft, the assist-plugs further are caused to engage the mold frame structure, through the intermediacy of the sheet, pivoting the frame structure and causing adjacent wall portions of the molds to move toward one another and assume their closely spaced position. Air entrapped between the heated sheet and the walls of the mold not provided with the auxiliary section is then evacuated through a number of small ports or vents in the Walls, thereby forming one of the desired liners, whereupon the auxiliary section of the other mold is projected and air entrapped between the heated sheet and the mold is evacuated, forming the other of the desired liners with an undercut region. The liners are then cooled, the extended auxiliary mold section is retracted from the undercut region, and the liners are stripped as a unit from the molds.

CROSS REFERENCE TO IRELATED DISCLOSURE This invention is directed to improvements in the method and apparatus disclosed and claimed in my copending US. patent application Ser. No. 73,761, filed Sept. 21, 1970, now US. Pat. No. 3,709,968, issued Jan. 9, 1973, and assigned to the assignee of the present invention.

BACKGROUND OF THE INVENTION This invention relates to the formation of articles from sheets of thermoplastic material, and is more particularly concerned with an improved method for forming deepdrawn shapes, for example food storage compartment liners for refrigerator cabinets.

In producing an article of the aforementioned type, it is known to bring an assist-plug contact with a heatsoftened sheet of thermoplastic material to urge portions thereof onto adjacent forming molds, after which the material is subjected to a vacuum, while in its heat-softened state, to achieve the desired shape. In the fabrication of liners for dual compartment refrigerators it has been desired to mold the liners from a single sheet, but it has been found difficult to achieve undercut regions in planar portions of the sheet, especially in the region of adjacency of the liner walls due to the close spacing therebetween.

It is a general objective of this invention to provide an improved vacuum-forming method which overcomes the above mentioned difiiculties, and which method is especially useful in the formation of vertically stacked, dual compartment cabinet liners.

SUMMARY on THE INVENTION In achievement of the foregoing as well as other objectives, the invention contemplates a novel method for forming from a single sheet of thermoplastic material dual compartment liners having unidirectionally presented openings, one of which liners includes an undercut recess in one of its walls. The invention is particularly characterized by the provision of a pair of adjacent, substantially unidirectionally presented molds one having the desired shape of one of the liners to be formed, and having vented wall sections. The other mold also is vented, and includes a section nested therein that is selectively extensible into the space between the molds, whereby, together with the mold, it atfords the desired shape of the other liner to be formed. The molds are mounted along base portions thereof on frame structure so hinged, in the region of adjacency of said base portions, as to provide for pivotation of the molds between a position in which confronting surfaces thereof are more widely spaced and a position in which the surfaces are more closely spaced. An assist-plug confronts the molds, and the plug and molds are relatively movable toward and away from one another in telescoping relationship.

In formation of a pair of liners, a sheet of thermoplastic material is placed'between the assist-plug and the molds. The sheet of material is then heated causing it to soften while the molds are held in their pivoted positions in which the confronting surfaces are more widely spaced. The assist-plug and mold structures are then moved relative to one another, to engage the heatsoftened sheet and urge it onto the molds. This movement is followed by interengagement of the two structures to urge the molds to non-pivoted, liner-forming position in which the confronting surfaces of the molds are in relatively closely spaced position. Air entrapped between the heated sheet and the mold not provided with the extensible section is then removed through large number of vents, or ports, in the Walls thereof, thereby forming one of the desired liners. Immediately, the auxiliary section of the other mold is projected, and air entrapped between the heated sheet and the other mold and its auxiliary section is evacuated, forming the other of the desired liners and its undercut region. Both liners are then cooled, the extended auxiliary section is retracted from the undercut region, and the liners are stripped from the molds.

For a further understanding of the invention, and the manner in which the objectives and advantages thereof may best be achieved, reference is made to the following description, taken in light of the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an elevational showing of refrigerator cabinet structure of a type embodying a pair of compartment liners made in accordance with the invention, and with the doors removed for convenience of illustration;

FIG. 2 is a sectional showing of the cabinet structure taken generally along the line indicated by arrows 22 applied to FIG. 1;

FIG. 3 is a sectional-elevational view of mold apparatus for fabricating the compartment liners of the cabinet seen in FIGS. 1 and 2;

FIG. 4 is a further showing of a portion of the apparatus seen in FIG. 3, and illustrating operational features thereof;

FIGS. 5 to 8 are additional views of the apparatus illustrated in FIGS. 3 and 4, and showing still further operational features thereof; and

'FIG. 9 is a perspective showing of a fragmented portion of the left hand mold section of the mold apparatus seen in FIGS. 3 to 8.

DESCRIPTION OF THE PREFERRED PRACTICE AND APPARATUS With reference to FIGS. 1 and 2, a refrigerator cabinet has a pair of compartments having undirectionally presented openings, and defined by a pair of liner sections 11 and 12. The liner sections are made of a thermoplastic material, and are molded as an integral structure from a single flat sheet of such material, in accordance with the invention to be described in detail below. Thermal insulation designated generally by the numeral 13, and which may for example be of the foamed type, fills the spaces between the confronting walls of liner section 11 and 12, and between the outer walls of the same sections and the walls of outer shell 14 of cabinet 10. It will be understood, of course, that other well known suitable types of thermal insulation may be used.

The refrigerating unit is conventional, comprising a compressor 15, condenser 16, and an evaporator 17 connected in the usual series flow circuit by suitable conduit means (not shown). Evaporator 17 is conveniently located in a recessed portion 21 of upper liner section 11, and a partition 22 includes a horizontal section that extends over the recess and the evaporator.

It will be appreciated that it has heretofore been found diflicult to mold recessed portion 21, and the present in vention is featured by a novel method and apparatus for molding liner structure including such an undercut section. Further to the exemplary refrigerator construction, partition 22 is provided with front air passages 23, and a vertical section 22a of the partition is spaced from the top and rear walls of liner section 11 as shown. Air moved by a blower 24 disposed in the rear portion of recess 21 is caused to flow into the freezer storage compartment defined by liner section 11, through the space between the liner and partition 22a, thence returns to the region of evaporator 17 through front passages 23. The lower food storage compartment, defined by liner section 12, is cooled by air caused to move from the compartment through passages 25, over evaporator 17, thence back into the compartment through passages 30.

From what follows, it will be appreciated that the present invention overcomes problems arising from: the characteristically close spacing between the above-described upper and lower liner sections 11 and 12, which heretofore has made it difiicult to vacuum-form the confronting top and bottom walls of the liners, due particularly to the relatively small amount of thermoplastic material available in the blank sheets for the relatively deep draw required in this region; and the fact that the recessed portion 21 of the upper liner section 11 comprises an undercut section, making it difficult to provide mold structure from which the molded liners may be easily stripped.

Turning now to apparatus for forming liners 11 and 12 in accordance with the invention, and first with reference to FIG. 3, an open top, generally box-shaped chamber 26 includes a pair of sub-sections 27 and 28, each separated from the other by a partition 29 and each ported, at 31 and 32 respectively, to suitable vacuum producing mechnism of conventional design (not shown). A clamping ring 33 closely surrounds the upper rim of vacuum chamber 26, and is constructed and arranged to clamp in place a sheet of thermoplastic material -M (broken line showing) that extends over the upper rim of chamber 26. A radiant heater 34 is arranged to overlie the sheet to heat the same, and is mounted for lateral movement (see horizontal arrows) between the illustrated extended position and a retracted position in which it is removed from above the sheet. An assist plug 35 of generally rectangular shape is disposed above heater 34 and has slightly rounded peripherally extending edge portions 36. In the illustrated embodiment, relative movement between the plug and the mold is provided for by mounting both assist plug 35 and the molds 37 and 38 for vertical movements, into and out of telescoping relationship, as will be described in detail. No apparatus for mounting assist plug 35 has been shown, since this apparatus can be entirely conventional in nature.

Each of the adjacently positioned, generally unindirectionally presented molds 37 and 38 is shaped to yield the general box shape of the inside surfaces of the respective liner sections 11 and 12 to be molded. Molds 37 and 38 are mounted along their base portions on articulated frame structure 40 hinged at 41 in the region of adjacency of the mold base portions. Use of two molds, and of hinged mold-supporting frame structure, i in accordance with the copending disclosure identified above. In especial accordance with the present invention, the left hand, smaller mold 37 includes an auxiliary section 42 conveniently shown in full lines, and nested in mold 37 .for selective extensible movement through opening 43 into the space between the molds 37 and 38, whereby in extended position it affords, together with mold 37, the desired shape of the smaller liner section 11 to be formed, as will be described in detail in an ensuing discussion of the operation of the mold apparatus.

As is seen to further advantage in FIG. 9, movements of auxiliary mold section 42 are afforded by a set of runners 44 on mold 37 that are slidably interengaged with a set of grooves 45 on a base portion 42a of the auxiliary mold section. Means for moving mold section 42 to and from its extended position on runners 44 includes a pair of links 46, each pinned to the mold section at 47 and to a pair of spaced bell crank 48 that are pivoted at 49 to mold 37. Bell cranks 48, only one of which is illustrated in FIG. 3 for the sake of convenience, further are pinned to the piston rod 51 of a pneumatic cylinder 50. The cylinder is pivoted at 52 to mold 37, and the construction and arrangement of the mechanism thus far described is such that extension of piston rod 51, by suitable introduction of pressurized air in cylinder 50, will rock crank 48 about its pivot 49 in a counterclockwise direction to move link 46 to the left and retract auxiliary mold section 42 to the position seen in FIG. 3. Conversely, retraction of piston rod 51 rocks crank 48 about pivot 49 in a clockwise direction, moving link 46 to the right and extending mold section 42 to the position seen in FIGS. 6, 7 and 9.

Frame structure 40 is ported, and molds 37, 38 and 42 are provided with large numbers of vents or ducts of a type appearing on enlarged scale at 53. Frame structure 40 further is supported for both sliding and pivotal movements on a generally rectangular open support frame 54 having a peripheral rim 55 that both confines and positions the molds. Support frame 54 is elevatable from the position shown in FIG. 3 to the upper position shown in FIG. 5, in which upper position the level of the frame structure 40, and mold base portions thereon, is substantially at the level of the upper edge of vacuum chamber 26. Conveniently, the upwardly pivoted position of frame structure 40 is maintained by mechanism including linkage means 56 described in the reference copending application, and which need not be described for an understanding of the present invention.

In further and more detailed accordance with the invention, partition 29 which divides chamber 26 is mounted to extend across and depend from frame support 54. Partition 29 further is slidably sealed, by suitable known means (not shown) to side walls of chamber 26, and is movable through a slot 57 in a lower, horizontal wall of the chamber, which slot 57 is rendered airtight by gasket means 58 that wipes the surface of partition 29. Suitable valving (not shown) is provided for vacuum ports 31 and 32 so that vacuums can be drawn independently on one or the other of the molds 37, 38, by way of corresponding chamber sections 27 and 28 communicating therewith.

In formation of a pair of liners 11 and 12, and again with reference to FIG. 3, a sheet of thermoplastic material, shown in broken lines at M, is placed between assist plug 35 and molds 37, 38. The sheet of material is then heated, causing it to soften and sag substantially to the position seen in broken lines at M, while molds 37 and 38 are held in their pivoted positions in which the confronting surfaces are more widely spaced. Heater 34 is then withdrawn, as is illustrated in FIG. 4, and the sagged sheet M (broken lines) is billowed upwardly to the position M (full lines) by application of slight, positive air pressure to chamber 26.

The assist plug and the molds are then moved relative to one another, to engage the heat softened sheet and urge it onto the molds 37, 38, while auxiliary mold section 42 is held in its illustrated retracted position. This movement, which is not illustrated, is then followed by interengagement of the two structures to urge the molds to non-pivoted, linear-forming position in which the confronting surfaces of molds 37, 38 are relatively closely spaced as is seen in FIG. 5. The left hand portion of the sheet is then draped over the mold 37, but does not conform closely thereto, particularly in the lower areas. Still with reference to FIG. 5, a vacuum is created in right hand chamber 28 by way of port 32, whereupon air entrapped between the heated sheet and right hand mold 38 is removed through the large number of vents or ports 53 in the walls thereof, thereby causing the right hand sheet portion to conform to the mold 38 and from the desired linear section 12, on mold 38, as shown. Immediately, and with reference to FIG. 6, the auxiliary section 42 of mold 37 is projected to its extended position by introducing pressurized air into the lower end of air cylinder 50 to rock crank 48 in a clockwise direction. As is seen in FIG. 7, and while auxiliary section 42 is held in its extended position, air entrapped between the heated sheet and mold 37, and its auxiliary section 42, is then evacuated to cause conformity to the mold 37 and thereby to form the desired liner section 11 and its undercut region 21 (FIG. 2). As is seen in FIG. 8, liner sections 11 and 12 are then cooled, the extended auxiliary mold section 42 is retracted from the undercut region of linear section 11, and the integrally formed linear sections are ready for stripping from the molds.

The method and apparatus contemplated by the invention readily accommodates formation of communicating passages between the upper and lower refrigerator compartments. Examples of such passages are the forward air passages 25 seen in FIGS. 1 and 2. These passages are provided for by confronting spaced protrusions 59 and 60 on molds 37 and 38, respectively. As will best be understood from FIGS. 6, 7, and 8, protrusions 59 and 60 cause overlying regions of the heated thermoplastic sheet to engage and thereafter permanently to adhere to one another. These regions of adherence are then pierced in suitable manner, following foaming in place of the insulation 13 shown in FIG. 2. Additional passages, such as the one designated by the numeral 30, may be formed by drilling through confronting liner walls and the interposed insulation 13.

While the invention has been described in connection with the formation of refrigerator compartment liners, it will be understood that the invention as claimed contemplates the formation of dual compartmented structures, generally, having undercut sections in wall portions thereof. Also, it will be understood that pressurized equipment may be used in place of the vacuum apparatus as shown and described for the application of differential fluid pressure to the softened thermoplastic sheet.

I claim:

1. In a method of forming a unitary article, comprising a pair of adjacent walled structures having unidirectionally presented openings, from a unitary sheet of thermoplastic material, utilizing a pair of substantially unidirectionally presented mold members shaped in correspondence to the structures to be formed and so associated as to be movable between one position in which confronting walls thereof are closely spaced in accordance with the spacing of the structures to be formed and another position in which said confronting walls are spaced apart a substantially greater distance than in said one position, the steps comprising: causing a unitary, softened sheet of thermoplastic material to extend over such mold members when the latter are in the mentioned other position in which the confronting walls of said members are substantially spaced; utilizing an assist plug to force said heat-softened sheet onto such mold members with a central portion thereof occupying space between the latter; moving said mold members to said one position in which they are closely spaced upon the recited movement of said assist plug; utilizing dif ferential fluid pressure to cause a first portion of said sheet to conform to the surface of one of said molds and withdrawing said assist plug from engagement with said sheet; causing a portion of the confronting surface of the other mold to project toward the like surface of said one mold; utilizing differential fluid pressure to cause a second portion of said sheet to conform to the surface of the other mold; retracting said projected mold surface portion; and removing said article from said molds.

2. The method according to claim 1, and characterized in that said mold members are pivotally moved between the recited positions.

References Cited UNITED STATES PATENTS 3,540,079 11/1970 Bush 264 X 3,058,153 10/1962 Busch 264-92 U X 2,784,455 3/ 1957 Pulaski 425388 X 3,337,664 8/1967 Lyon 264-92 X 3,709,968 1/1973 Houghton 26492 ROBERT F. WHITE, Primary Examiner I. H. SILBAUGH, Assistant Examiner U.S. Cl. X.R. 

